Building panel

ABSTRACT

A building panel is provided for affixing to above-grade exterior building surfaces, the building panel comprising: opposed front and back sides generally parallel to each other; opposed top and bottom edges generally parallel to each other; a generally horizontal groove in the top edge spaced from the front and back sides; and at least one generally vertical channel extending downwardly from the generally horizontal groove through the building panel to the bottom edge at a point on the bottom edge spaced from the front and back sides. The building panel is preferably for thermal insulation and for collection and drainage of moisture from water vapour, and is preferably used in conjunction with exterior insulated finish systems.

FIELD OF THE INVENTION

The present invention relates to building panels, and more particularly to building panels directed to moisture drainage.

BACKGROUND OF THE INVENTION

In the context of exterior building panels, the presence of moisture can lead to undesirable results. Moisture that becomes trapped within and between panels can generate rot in the substrate to which the panel is affixed, it can bleed through the panel finishing coat and discolour it, and it can even cause the panel to detach from the substrate.

Prior attempts to address this problem include Canadian Patent 1,220,041 to Larsson, which teaches a panel having drainage channels for use with subterranean wall surfaces. The channels communicate directly with the subterranean wall surface, as the channels are intended to direct water accumulation on the concrete surface away from that concrete surface. U.S. Pat. No. 6,318,041 to Stanley discloses a panel system that also employs drainage channels, although in this case the drainage system is directed to the release of moisture trapped within the cellular structure of the panels.

While various attempts have been made to address the problem of moisture in a variety of building panel contexts, a need has been felt for an improved means of addressing the problem in the specific context of Exterior Insulated Finish System (EIFS) technology. The EIFS system, developed in Europe in the 1950s, uses multi-layered exterior wall systems for both commercial and residential buildings, and it typically consists of an interior insulation board secured to the exterior wall surface, a reinforced base coat applied to the insulation board, and a finish coat that is both visually attractive and resistant to environmental impact. The superior energy efficiency and design flexibility of the EIFS system have resulted in growing popularity, but the presence of moisture remains a vexing problem.

SUMMARY OF THE INVENTION

According to one aspect of the present invention there is provided a building panel for affixing to above-grade exterior building surfaces, the building panel comprising:

-   -   opposed front and back sides generally parallel to each other;     -   opposed top and bottom edges generally parallel to each other;     -   a groove in the top edge spaced from the front and back sides;         and     -   at least one channel extending from the groove through the         building panel to the bottom edge at a point on the bottom edge         spaced from the front and back sides.

In use, the panel is installed with the top and bottom edges generally horizontal and the front and back sides upright.

In exemplary embodiments of the present invention, the building panel comprises a thermally insulating material. It provides thermal insulation while serving for the collection and drainage of moisture from condensed vapour,

The building panel suitably comprises an expanded polystyrene or polyisocyanurate material.

The generally horizontal groove is preferably V-shaped in cross section and configured to facilitate lateral movement of moisture from condensed vapour to the vertical channels which provide a path for downward flow of the moisture.

The vertical channel is preferably rectangular in cross section. The building panel is preferably a moulded, monolithic body.

By providing a building panel that can both insulate and efficiently direct moisture from water vapour away from the panels and underlying substrate, while serving the need for an even surface for application of the base and finish coats, the present invention is intended to address a pressing need in the industry.

A detailed description of an exemplary embodiment of the present invention is given in the following. It is to be understood, however, that the invention is not to be construed as limited to this embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings, which illustrate an exemplary embodiment of the present invention:

FIG. 1 is a side cross-section along line I-I in FIG. 2 of an in situ assembly of building panels according to the present invention;

FIG. 2 is a front elevation of the assembly of FIG. 1; and

FIG. 3 is a plan view of a building panel according to the present invention.

DETAILED DESCRIPTION OF AN EXEMPLARY EMBODIMENT

Referring now in detail to the accompanying drawings, and particularly to FIGS. 1 and 2, there is illustrated an assembly of building panels according to the present invention, each panel being referred to generally by the numeral 10. The building panel 10 comprises opposed front and back sides 14, 16 generally parallel to each other, opposed top and bottom edges 18, 20 generally parallel to each other, a generally horizontal V-shaped groove 22 in the top edge 18 spaced from the front and back sides 14, 16, and generally vertical channels 24, each extending downwardly from the groove 22 though the building panel 10 to the bottom edge 20 at points on the bottom edge 20 spaced from the front and back sides 14, 16. While FIG. 2 shows the channels 24 only in the centrally positioned building panel 10, the channels 24 are also in each of the adjacent building panels 10. The building panel 10 is a moulded, monolithic body, which is an advantage over traditional wire-cut construction.

As can be seen in FIG. 1, the back side 16 of the building panel 10 is affixed by an adhesive 28 to a trowel-on membrane 26 applied to the exterior surface 12 of a building 13 as an air/vapour barrier. In the illustrated embodiment, the adhesive 28 is applied as a layer prior to positioning of the building panel 10.

The utility of the present invention becomes clear in the following situation. When it is determined that a particular exterior building surface 12 is suitable for application of the building panels 10 (suitable substrates include, but are not limited to exterior grade drywall, cement board, plywood sheathing, Dens-Glass sheathing, precast concrete, concrete block, or poured-in-place concrete). An air/vapour barrier membrane 26 is applied to the exterior building surface 12, preferably as a trowel-on layer. An adhesive 28 is then applied on top of the membrane 26, and a reinforcing mesh (not shown) such as glass fabric reinforcing mesh is embedded in the adhesive 28. The building panels 10 are then applied over this adhesive layer 28 and secured in place thereby. For a building of four stories or greater it is advisable to use mechanical fasteners as well to secure the panels to the exterior building surface 12. The building panels 10 are preferably arranged in the offset pattern shown in FIG. 2, a pattern well known in the art. The joints between the building panels 10 should be sealed with a suitable material (not shown) known to those skilled in the art to further enhance the insulating properties of the building panels 10. Various methods of providing base and finishing coats (not shown) are then possible, according to the general knowledge of those skilled in the art of EIFS use. With the building panels 10 now in place on the exterior building surface 12 and finished in a suitable manner, the groove 22 is now configured to facilitate lateral movement of moisture from water vapour and residual moisture to the channels 24 for downward flow of the moisture through the channels 24. Moisture can flow horizontally through a groove 22 and into adjacent grooves 22 as necessary, while the channels 24 then provide vertical moisture drainage means for the moisture flowing through the grooves 22.

While a particular embodiment of the present invention has been described in the foregoing, it is to be understood that other embodiments are possible within the scope of the invention and are intended to be included herein. Thus, while the embodiment illustrated in FIGS. 2 and 3 includes fifteen equally-spaced channels 24 per building panel 10, but it may be preferable to have nineteen or some other number of channels 24 depending on the application. While particular substrates have been identified in the foregoing, it is to be understood that the application of the panel to any substrate is to be considered within the scope of the invention. Currently it is considered that the invention may not be especially useful with certain types of substrate, including oriented strand board and chipboards. It will therefore be clear to those skilled in the art that modifications of and adjustments to this invention, not shown, are possible without departing from the spirit of the invention as demonstrated through the exemplary embodiment. The invention is therefore to be considered limited solely by the scope of the appended claims. 

1. A building panel for affixing to above-grade exterior building surfaces, the building panel comprising: opposed front and back sides generally parallel to each other; opposed top and bottom edges generally parallel to each other; a groove in the top edge spaced from the front and back sides; and at least one drainage channel extending from the groove through the building panel to the bottom edge at a point on the bottom edge spaced from the front and back sides.
 2. The building panel of claim 1 wherein the building panel comprises a thermally insulating material.
 3. The building panel of claim 1 wherein the building panel comprises expanded polystyrene or polyisocyanurate.
 4. The building panel of claim 1 wherein the groove is substantially V-shaped in cross section.
 5. The building panel of claim 1 wherein the at least one drainage channel is rectangular in cross section.
 6. The building panel of claim 1 wherein the building panel is a moulded, monolithic body.
 7. The building panel of claim 2 wherein the generally groove is configured to facilitate lateral movement of water along the groove to the at least one channel for drainage of the water through the at least one drainage channel. 